Machine for the manufacture of concrete building units



Oct. 3, 1961 c. w. JACKSON MACHINE FOR THE MANUFACTURE OF CONCRETEBUILDING UNITS Filed March 18, 1957 m 1 t E m m w N] H N Q N w m 1 a w ww m I I N m h S vv A m .7 2 4 w rd @E m. q I a n .1 6 n El b a 2| t 1" v-w Q R. f Q Q R Q 0 a J Oct. 3, 1961 c. w. JACKSON 3,002,249

MACHINE FOR THE MANUFACTURE OF CONCRETE BUILDING UNITS Filed March 18.1957 4 Sheets-Sheet 2 15+ @6 2 A 'IIIIIIIIIIII/ll \WA 'IIIIlIIIIIII/Il.

-INVENTOR. CLARENCE W.J.4c/ so- Vmm/J- HEY Oct. 3, 1961 c. w. JACKSON3,002,249

MACHINE FOR THE MANUFACTURE OF CONCRETE BUILDING UNITS Filed March 18,1957 4 Sheets-Sheet 3 a 44 50 m EINVENTOR.

6m EENCE W- .l cksou T0 ENE Y United States Patent 3,002,249 MACHINE FORTHE MANUFACTURE OF CONCRETE BUILDING UNITS Clarence W. Jackson, 605Minor Ave., Apt. 106, Seattle, Wash. Filed Mar. 18, 1957, Ser. No.646,734 3 Claims. (Cl. 25-99) This invention relates primarily to ameans for the expeditious and economical manufacture of what will hereinbe referred to as concrete building units; the word concrete in thisinstance being used to designate the usual or a special mixture ofcement, sand, gravel and water, and/ or other aggregate, plastic ormoldable hard setting materialwhich can be used in a manner likeconcrete to form building units of the present type.

More specifically stated, the present invention has to do with themanufacture of concrete units which may be like, or of the generalcharacter of the units illustrated and described in my abandonedapplication filed on Dec. 3, 1956, under Serial No. 625,861; theparticular building units therein disclosed being of rectangular orSquare slab form, of predetermined modular dimensions and each beingadapted to be assembled with others of like kind to form a wall withclosed, interfitted and interlocked weather tight joints through which aweight sustaining continuity is provided without use of mortar or otherjoint sealing materials.

One ofthe principal objects of the invention is to provide a machine, orapparatus for carrying out a method of manufacture and which machinemakes possible the desired high rate of production of units with exactprecision in their predetermined dimensions.

Still another object of this invention resides in the provision of apractical and economical mechanical apparatus for the desired high speedmanufacture of the present units.

Still another object of the present invention is totprovide anapparatus'for the high speed manufacture of: con crete units of modulardimensions, and to establish those dimensions with such exactness ofprecision that, in the building of a wall, the units maybe laidjup incourses, end to end and edge to edge, inv closed, interfitted andinterlocked horizontal and vertical joints that require no joint sealingmortar.

Still further objects of the present invention reside in the variousdetails of construction and combination of parts embodied intheapparatus; in the details of the concrete units per se, and in thespecificsequence-of steps as followed in carrying out the present methodof high speed, precision manufacture of the units.

In accomplishing the above mentioned and other objects of the invention,I have provided a unit manufacturing apparatus embodying improveddetails of construction and have-designed specific forms of buildingunits to be manufactured thereby; the preferred form of apparatus andthe preferred desgin of units being, illustrated in the accompanyingdrawings, wherein:

FIG.v 1 is a plan, or top view of an apparatus designed for the rapidmanufacture of concrete units embodied by this. invention in exactprecision of dimensions.

FIG. 2 is an. enlarged plan view of that portion of the apparatusenclosed by the circularly directed arrow in FIG. 1.

FIG. 3 is a vertical section of the apparatus, taken on theline 3-3 inFIG. 1.

FIG. 4 is an enlarged vertical sectional view of apart of the apparatus,particularly showing the face to face, engagedrelationship, of end railsof adjacent, compound formsas advancing throughthe mac ine.

FIG. 5 is an enlarged, vertical cross-section of the present apparatustaken on the line 5-5 in FIG. 1.

FIG. 6 is an end view of a compacting roll and a side view of a part ofone of the compoundv forms as passing under the roll.

FIG. 7 is a vertical section taken on line, 7--7 in FIG. 5.

FIG. 8 is an enlarged vertical section taken on line 88 in FIG. 3,showing a part of one of the shaper rolls and its mounting.

FIG. 9 is an enlarged transverse sectional detail, taken on line 99 inFIG. 1.

FIG. 10 is an enlarged sectional detail taken through the hoppers online 10-10 in FIG. 1.

FIG. 11 is an exploded view of one of the compound forms within whichthe individual unit frames are contained for filling with concrete asadvanced through the mechanism.

FIG. 12 illustrates some of the various forms which may be given thecompacting and shaper rolls when units with special surface contours orshapes are desired.

Referring more in detail to the drawings:

The specific building unit to be manufactured in accordance with thesteps of the present method and by use of the apparatus or means of thisinvention, is ofrectangular form and of such limited thickness withrespect to its other dimensions that it can be considered to be of slaform. As presently manufactured, the unit is sixteen inches long, eightinches wide and one and onehalf inches thick; these dimensions beinghere mentioned only for the purpose of imparting a better understandingof the type or character of the unit, and are not to be considered inany way as. dimensional limitations. The unit is made of concrete, aspreviously defined, and the specification for the concrete used" in. itsmanufacture would ordinarily be according to local building codes,requirements or desires of the builder and are not herein definitelyestablished. However, it is desired here to emphasize that the thoughtbehind the present invention, as embodied both in the mechanism for andin the method of manufacture, is to make possible the manufacture ofunits at a high rate of production and with exact precision in alldimensions. To this end it becomes necessary to not only design-anapparatus, including the frames and for-ms in which the units aremolded; with extreme exactness in predetermined dimensions, but also totake into consideration "all the physical properties of the aggregatematerials as well as the atmospheric conditions in which manufacturingis to be carried out;

The present concrete unit has flat, parallel inside and outsidesurfaces; it is square cornered and its, bounding edges are formed withtongues and grooves, as illustrated; to provide for an interfitted andinterlocked edge to edge relationship of units when laid up inhorizontal courses. However, it is to be understood that, insofar aseither the method or apparatus of this invention is concerned, eachapplies equally to the making of units with plane edges or with edgeformations of various other kinds.

One of the features of the present concrete unit resides in its beingmolded or formed within a frame, form or edge binding of sheet metal,plastic or other suitable material, made exactly to predetermined.dimensions. for the desired modular unit, which is adapted to be easilyremoved from the unit to ready it for use but which, until that time,serves to strengthen, and protect the unit against edge chipping,handling. damage or cracking. Furthermore, such frames serve to. retainthe units in form for easy handling especially while green,andimmediately after their removalv from. .thecompol nd. molds in whichthe units are made.

Each unit comprises a solid, rectangular, molded concrete body withflat, smooth, parallel opposite faces; the body in the present instancebeing provided to its full length along its top edge and centrallybetween the planes of its inside and outside surfaces, with an integral,square cornered tongue. Likewise, the body is formed along one of itsvertical end edges with a square formed tongue. Also, each unit isformed in and along its bottom horizontal edge and in its other verticalend edge, respectively, with similarly dimensioned grooves.

Each of the units in the form above described, is originally enclosed bythe protective, edge binding or frame 20 previously mentioned.

In FIG. 5, I have shown the unit as containing reinforcing rods 30 of apredetermined form and embedded 1n the unit, lengthwise thereof, andsymmetrically spaced from its opposite longitudinal edges. These rodshave angularly turned opposite end portions, 31-31, tack welded for easyrelease, to the opposite end members of the frame 20, thus to hold therods properly placed therein preparatory to the frame being filled withconcrete. It is shown also that each of the rods 30 is bent intermediateits ends to form two downwardly projecting U- shaped loops 32 which willextend slightly from the inside surface of the finished unit. It is alsoshown in FIG. that the unit contains a plurality of transverse, spacedreinforcing rods 33; these being spot welded to the longitudinal rods30, thus to hold them in proper position prior to and while the framesare being filled with concrete.

It is to be understood that although I have illustrated a machine forthe mechanical manufacture of the present units, manufacture could 'bequite satisfactorily carried on manually, that is, by hand filling theframes with concrete tamping it to proper compactness therein, smoothingoff the surfaces and allowing the concrete to set in the frames 20;these being removed from the units preferably at the time of their beingput to use. However, the economic practicability of the use of thepresent concrete units resides, in part, in their rapid manufacture.Hand manufacture would not ordinarily be commercially feasible, and itis for this reason that the present apparatus, providing for high speedproduction, has been devised.

An apparatus or machine designed for the high speed manufacture of thepresent types of units is shown in FIG. 1. It comprises an elongatedbase or frame structure of table-like form made up of longitudinal,laterally spaced opposite side beams 3535, extended to its full lengthand supported at the same convenient working level by legs 36 arrangedat suitable intervals therealong. It is to be understood that this tablestructure can be given the necessary rigidity by suitable cross andlongitudinal bracing. The table top, for the greater part, is made up ofa succession of rather closely spaced, transverse rollers 38, all of thesame diameter and all supported at the same horizontal level; theserollers being formed with trunnions. 38' at their opposite ends,rotatably contained in bearings 39 fixed in or to the longitudinal beams35- 35, as seen in FIG. 5.

Mounted on the top surfaces of the beams 35-35, in alignment and atrather closely spaced intervals therealong, are form guide rollers 40and between these two parallel rows of rollers, the compound frameenclosing forms, presently to be described, are adapted to besuccessively advanced end to end, for the filling of their containedframes with concrete thus to form the individual units. The rollers 40,as shown in FIG. 1, are all of the same diameter, and most of them aremounted to rotate freely on vertical stud spindles 41, best shown in"FIGS. 2 and 9, that are fixed to the beams 3535. The others arerotatably driven, as will presently be explained, for the advancement ofthe compound forms through the machine.

The lateral spacing of the two rows of aligned guide rollers 40, asapplied to the two laterally spaced beams 35-35, is a predeterminedmeasurement, exactly equal to the outside width of the compound forms.The compound forms, each containing a plurality of frames 20, aresupported for advancement and the filling of the frames, upon thecross-rolls 38, and are guided by and between the rows of rollers 40.

The compound forms as provided for the reception of the presentrectangular frames 20, are presently of such length as to accommodateten frames, but it is to be understood that they may be made toaccommodate a greater or a lesser number, according to desires. Each ofthe compound forms is made up of a plurality of easily assembled anddisassembled parts, best shown in FIG. 20. Each form comprises parallel,opposite side rails 4242 of the same length. Eleven cross-bars 43 areassembled with these side rails, at equal spacing thus to define tencompartments. Within each compartment thus formed one of the metalframes 20 is contained and securely held. The present operationcontemplates the assembling of the frames 20 with the compound forms atone end of the machine; the advancing of the frame containing forms, endto end, into the machine at that end, the filling of the frames as theysuccessively pass the aggregate and surface finishing materialcontaining hoppers, then the compacting of the aggregate in the framesand, as the forms reach the discharge end of the machine, thedisassembling of the forms, and the carrying of the filled frames ontheir pallets, to a place where the units are left to cure. Y

Referring now more particularly to FIG. 11, it is to be observed thatone of the longitudinal rails 42 of the compound form is formed in itsinside surface and to its full length with a channel 47, and theopposite rail 42 is formed likewise with an intermittent longitudinalrib 46 extended to its full length.

The cross-bars 43 are all of the same length and each, except those atthe opposite ends of each form, is formed lengthwise thereof on one sidewith a rib 46 and in its opposite side with a channel 47. When crossbars and side rails are assembled and interfitted, ribs and channels ofbars register with the ribs and channels of the rails 42-42. At theiropposite ends, all cross-bars 43 are square cut and, in the assembly ofparts, are seated in recesses 48 formed vertically through the insidesurfaces of the rails 42-42 at exact, predetermined intervals as shownin FIG. 11. It is further to be observed in this view, that thesuccessive portions of tongue 46 are extended slightly, as at 46x, so asto enter the bar grooves 47'. Also, it will be understood that the endportions of the cross-bar tongues 46 likewise will enter the rail groove47. The compartments that are formed by the assembly of the oppositeside rails 42-42 and cross-bars 43, 43, are adapted to snugly containthe frames 20 therein.

It is to be noted in FIG. 11 that the cross-bar 43' used at the oppositeends of the compound forms, are provided by longitudinally splitting oneof the regular crossbars 43, thus they are only of half width, as willbe understood by reference to FIG. 13; such half bars are designated bynumeral 43'.

For a convenient assembly of frames 20 in the compound forms, I haveprovided an assembly table 44 at the receiving end of the machine. Thiscomprises a flat table surface preferably at the same level as therollers 38.

Preparatory to the assembling of metal frames 20 within a compound form,they are placed transversely of the table 44 and in a row aligned withthe machine, each resting upon a rectangular pallet 49 of substantiallythe same length and width; it being understood that these pallets areprecision formed of metal as are all the other parts of the form so thatthere is a precision fit of the frames therewith in the final assemblyof parts. The cross-bars 43 are placed between adjacent frames, and thesplit half-bars 43' are located at the opposite ends of the form. Thenthe longitudinal rails 4242 are broughtinto position to receive the endsof the cross bars 43 within the rail recesses 48. As these parts 42-42and 4343 are thus assembled and interfitted, the rectangular pallets 49are received between them and in seats 50 formed in the lower edges ofthe cross-bars, and at their ends in seats 51 formed in the lower, inneredges of the opposite side rails 42-42. All pallets are exactly of thesame size, and when firmly seated at their edges in the seats providedin the cross-bars and rails, they serve to square up the assembly ofparts and give the desired rigidity to the form. It is to be understoodalso that in the assembling of these compartment defining parts with themetal frames 20, the tongue and groove defining portions of the framesand forms are caused to be snugly interfitted. This adds rigidity to theassembly and maintains the proper-relationship of the assembled parts asadvanced between the two rows of rollers 40 for filling of the frames.Also, the metal frames rest with their lower edges seated firmly againstthe individual supporting pallets 49 as noted in FIG. 4. All frames areexactly equal in height and each defines the Width, length and depth ofthe unit to be formed therein. In the advancing of the'compound formsthrough the machines, the forms are held against spreading between therows of guide rollers 40-40- and thus their rigidity is assured.

When the frames 20 contain reinforcing rods of the form disclosed, it isnecessary that the supporting pallets be provided with slotstherethrough for passage of the anchor loop forming portions of therods. Such. slots have been designatedin FIG. by numeral 54.

For filling the metal frames 20 with concrete as confined in thecompound molds, I provide a hopper 60 supported by and above the framestructure of the machine at a location near its entrance end. Thishopper is of box like form, with vertical opposite side walls, andvertical end walls.

It is shown in FIG. 9 that the lower edges of the sidewalls extend downbetween the rails 4242, just within the vertical planes of theends ofthe frames, and close to the level of their top edges. It is to beobserved in this view alsothat the rails 42.42 are of greater heightthan the cross-bars 43, and thus the extending of the hopper walls downwithin. the rails is possible without their contacting. with thecross-bars as the forms are advanced. A prepared aggregate 61 iscontained in the hopper and it is adapted to. feed downwardly therefrominto the frames, as they are successively advanced thereunder; feedingbeing effected under the influence of any suitable form of mechanicallyoperated. vibrating devices located at .suitablev places onthe framestructure or on the hopper, for example, as indicated. at 62 in FIGS.9'and 10 It is further to be understood that the arrangement andcharacter of the, vibrating means, and the manner of their control isdependent on the materials of the aggregate.

Also supported on the frame structure, beyond the hopper 60, as noted inFIGS. 1 and 3, is a second and smaller hopper 63, beneath which thecompound forms are advanced after receiving the filling material fromthe hopper 60. From the hopper 63 a thin surfacing layer of finefinishing material 64, is fed automatically onto the top surfaces of theconcrete units to a predetermined thickness. The level to which thefilling material is fed into the frames is controlled by verticallyadjustable gates 60x and 63x attached respectively to the ends walls ofthe two hoppers as best shown on FIG. 3. In each case the lower edge ofthe gate establishes the top level of the material fed to the frames.

Beyond the hopper 63 are one or more transverse rolls v65 which operateas the filled frames pass thereunder to roll on and compact theaggregate and its over-layer of finishing material to smooth down thetop surfaces of the units to a predetermined and uniform level. In thepresent instance only one roll 65 has been shown. These rollshave-trunnions 65 at their ends contained as in FIG. 5; for a slightvertical movement, in retaining bearings 66 that are mounted on the siderails 35-35 of the main frame structure. It is the intent that theframes 20 be filled from the hoppers to such extent, and that the Weightof the rolls 65 shall be effective, as they roll on the aggregate, tocompact it and bring the top surfaces of all units flush with the topedges of their containing frames.

Various means may be employed for the mechanical advancement of thecompound forms with their assembly of frames 20 through thefillingmechanism, or, if it is so desired, these forms could be advancedmanually. However, in the present instance it is preferred that theiradvancement be effected by driving certain of the guide rollers 40 byand between which the compound frames are guided. For this purposeselected rolls 44) at opposite sides of the main frame and at a suitableintervals therealong are fixed on the upper ends of verticalshafts 68,and these paired shafts are joined to rotate in proper direction and inunison. It is shown in FIG. 5 that bevel gears 70 are fixed to the lowerends of paired vertical shafts 68 and bevel gears 71 on a drivencross-shaft 72 mesh therewith. Driven rollers, as above arranged, arelocated at necessary intervals along the table to insure the advancementof the compound forms without interruption when placed end to endand'the several crossshafts 72 are driven in unison, each by a gearedconnection'as at 75, with a line shaft 76. Drive rollers 4t! may beequipped with suitable friction tires for this purpose.

In order that the cross-bars 43, as applied in the compound forms maypass freely under the compressing rolls 65 without the rolls causing anyimpact therewith, such as would result in the event that layers offinishing material should remain on the top surfaces of the bars, therolls are formed from end to end with longitudinal surface channels 78,located therein at a circumferential spacing that is equal to the linealspacing between bars 43 as contained in the compound forms. The properindexing of each roll 65 to cause the channels 78 to register with thecross-bars with clearance as they pass beneath the rolls, is effected asfollows: Each roll 65- is formed at its opposite ends with diametricallyreduced hubs 65x of the same diameter. These hubs extend across and mayroll on the top surfaces of the longitudinal side rails 42-42 of theadvancing forms as they pass thereunder. Each roll 65 is held againsttravel along the table by reason of its end trunnions being confined inthe bearings 66, and the rollers or shapers will roll upon the concreteor aggregate as contained in the frames 20 to-compact it. The hubs 65xare formed at regular intervals circumferentially thereof withtransverse ribs or teeth 81, here shown to be of -U-shape, that areadapted to register in complemental notches 82 formed in the topsurfaces. of the form rails 42-42,thus to maintain the properregistering relationship between the channels 78 of rolls 65 andcross-bars 43' of the forms.

Immediately following the aggregate compacting rolls 65, one or moretroweling rolls 85 are mounted transversely of the frame by bearings 86fixed to the rails 3535. These rolls are in constant contact withmoistening wicks 87 and roll on the top surfaces of the concrete in thefilled frames. These rolls are channeled as are rolls 65 and areequipped in like manner with means whereby their proper registration ismaintained with the forms as advanced thereunder.

As the frame enclosing compound forms are received at the discharge endof the machine, they pass from between the laterally spaced rows ofguide rolls 40 onto a dis-assembly table, not shown. The side rails 4242are pulled apart thus to free the cross-bars therefrom, permitting thefilled frames 20 to be separated and conveyed on their individualpallets 49 to storage for drying or curing.

The dis-assembled rails and cross-bars are subsequently returned to theassembly table at the receiving end of the 7 machine, and made ready forre-use. Here they are assembled with pallets and new frames, and theform then advanced into the machine and the filling process is repeated.

In my abandoned application, previously mentioned, a disclosure was madeof concrete units of the present character, formed with corrugatedsurfaces for ornamental or functional purposes. It is desired to herenote that such units with corrugated, convex, concave, grooved, ribbedor other surface forms may be made merely by the use of feed gates forthe material hoppers, and use of compacting and shaper rolls havingcontours which will give to the concrete units, the selected surfaceformation; it being understood, of course, that the side rails andcrossbars constituting the compound forms and frames 20 if used, alsowould be made in such manner as to accommodate the requirements.

In FIG. 12 three difierent forms of rolls have been illustrated. Roll65x is designed for use when a unit with a concaved outer surface isdesired; roll 65y is designed for use where units with convex outersurface is desired and rool 65z is for the making of units withcorrugated surface. These shapes apply in each instance to all the compacting and shaper or troweling rolls.

When such rolls are used, the feed gates 60x and 63x would have theirlower edges curved accordingly. Likewise, the top surfaces of thecross-bars of the compound forms would conform to the selected surfacecurvature as would also the surfaces of the compacting or shaper rolls.

It is also to be understood that insofar as the manufacture of concreteunits of the types disclosed is concerned, the machine can be easily andreadily adapted to make the various surface formations mentioned, andalso units can be made with or without use of the protective metalframes 20 but would necessarily require a certain curing period in thecompound forms.

It is further anticipated that the present operation of advancing theunit frames along an established path of travel and beneath stationaryrolls for the compacting and surface shaping operations, could also beaccom plished in a satisfactory manner, by mounting the frames 20 andcompound forms in a stationary horizontal position and then causing thehoppers and rollers to be advanced thereacross to accomplish the formfilling and then the compacting and shaping operations. However, thislatter procedure probably would be more expensive and less practical.

What I claim is:

1. A machine for the manufacture of concrete building units of slab formcomprising a conveyor table, means establishing opposite side limits ofa straight path of travvel of uniform width along the table top, anaggregate storage and feeding hopper supported above and across saidpath of travel, a compound form disposed on said table for guidedendwise advancement in said path of travel along said table, saidcompound form comprising an easily separable assembly of parts includingopposite side rails, a plurality of transverse divisional membersextending between the side rails defining a succession of identicalcompartments in said compound for-m, and a pallet fitted in the bottomof each compartment, means for advancing the compound form along theguideway for the filling of its compartments from the hopper in passingbeneath it, and an aggregate compacting roller mounted above andtransversely of said path of travel; said roller having a cylindricalbody portion for rolling and compacting contact with the aggregate inthe compartments of the form as it is advanced beneath the roller andhaving diametrically reduced opposite end cylindrical hubs of equaldiameter disposed for rolling support on the top surfaces of theopposite side rails of the advancing compound form, and said hubs havingteeth formed on their cylindrical surfaces at equal distances of angularspacing; said opposite side rails of the compound forms being providedwith notches in their top surfaces, in such lineal spacing as to receivesaid teeth in interfitting mesh therein as the form advances, thus tosynchronize the rotation of the roller with the advancement of thecompound form.

2. A machine according to claim 1, wherein the means defining theopposite side limits of said straight path of travel comprises, asuccession of form guiding rollers of the same diameter, and spaced atpredetermined intervals to cooperatively engage in rolling contact withthe corresponding side rails of the compound form in its advancementalong said path of travel.

3. The machine of claim 2, wherein means is provided for rotatablydriving some of said path defining and form guiding rollers at each sideof the path for their positive advancement of the compound form alongthe path of travel.

References Cited in the file of this patent UNITED STATES PATENTS1,377,188 Domine May 10, 1921 1,559,499 Brandell Oct. 27, 1925 1,750,113Martin Mar. 11, 1930 1,998,117 Brush Apr. 16, 1935 2,004,936 Dorn June18, 1935 2,091,140 Davis Aug. 24, 1937 2,129,162 Robillard Sept. 6, 19382,288,611 De Wyk July 7, 1942 2,294,556 Henderson Sept. 1, 19422,462,415 Nagel Feb. 22, 1949 2,531,574 Lang Nov. 28, 1950 2,674,775Willson Apr. 13, 1954 2,734,249 Willis Feb. 14, 1956 2,752,656 RutgersJuly 3, 1956

